DESIGN AND FABRICATE OF SECURED LCD REMOTE CONTROL HOLDER IN UMP
PEKAN LECTURE ROOM
FARIS SYAFIQ BIN ZAKARIA
Report submitted in partial fulfillment of the requirements
for the award of Diploma in Mechanical Engineering
Faculty of Mechanical Engineering
UNIVERSITI MALAYSIA PAHANG
DECEMBER 2010
ii
SUPERVISOR’S DECLARATION
I hereby declare that I have checked this project report and in my opinion this
project is satisfactory in terms of scope and quality for the award of Diploma in
Mechanical Engineering.
Signature:
Name of Supervisor: Miminorazeansuhaila Binti Loman
Position: Lecturer
Date: 5 December 2010
iii
STUDENT DECLARATION
I hereby declare that the work in this report is my own except for quotations and
summaries which have been duly acknowledged. The report has not been accepted for
any degree and is not concurrently submitted for award of other degree.
Signature:
Name: Faris Syafiq Bin Zakaria
ID Number: MB08047
Date: 5 December 2010
iv
ACKNOWLEDGEMENT
Praise to God for His help and guidance that I am able to complete the task of the
Final
Year
Project.
I am thankful
and
grateful to
my supervisor,
Mrs
Miminorazeansuhaila Binti Loman for her advice and knowledge that she shared in the
completion of the project. I appreciate her help for me while I am doing the Final Year
Project from week 1 to the day I finished my Final Year Project.
I also would like to thank all my friends who have been really helpful during the
course of the conducting the Final Year Project. I also would like to thank laboratory
assistants especially to Mr Aziha Bin Abdul Aziz and who have help me in conducting
machine and sharing knowledge in conjunction with the project that I am conducting.
I sincerely grateful to my parents, Zakaria Bin Hassan and Salmah Binti Ismail
for they love and sacrifice that they had for me throughout my life and their support for
me in all my activities that I have done. I also wanted to that other people who have
directly or indirectly help in the completion of my Final Year Project. I sincerely
appreciate all your help.
v
ABSTRACT
This report shows the design and fabrication of a secure LCD remote control
holder. The objective of the report is to design and fabricate a secure LCD remote
control holder. This report also describes the remote holder products which are available
around the world with its safety criteria. Design generation is showed and solid three
dimensional structures modelling of the remote control holder was developed with
computer aided design software. This report also explains the fabrication process that is
needed for this project. Material that is being used in this project is zinc sheet metal and
mild steel bar, shaft and hollow shaft. The problems encountered during completion of
this project are also show in the report. An idea of improvement for the remote control
holder is also provided to further improve the remote control holder. The expected result
for this project can solve the entire stated problem statement.
vi
ABSTRAK
Laporan ini menunjukkan lukisan dan pembuatan pemegang alat kawalan jauh
LCD yang selamat. Objektif laporan ini adalah untuk lukisan dan pembuatan pemegang
alat kawalan jauh. Laporan ini juga menerangkan tentang produk-produk pemegang alat
kawalan jauh yang terdapat di serata dunia dan cirri-ciri keselamatan. Konsep lukisan
telah ditunjukkan dan permodelan struktur-struktur bongkah tiga dimensi untuk
pemegang alat kawalan telah dihasilkan menggunakan perisian lukisan bantuan
komputer. Laporan ini juga menerangkan proses pembuatan yang diperlukan untuk
projek ini. Bahan yang akan digunakan dalam projek ini ialah kepingan zink dan
beberapa jenis logam asli. Masalah yang dihadapi semasa menyiapkan projek ini juga
terdapat di dalam laporan ini. Idea penambahbaikan untuk pemegang alat kawalan jauh
juga disediakan untuk pembaharuan masa akan datang. Keputusan yang dijangkakan
bagi projek ini ialah dapat menyelesaikan segala penyataan masalah yang telah di
nyatakan.
vii
TABLE OF CONTENTS
Page
SUPERVISOR’S DECLARATION
ii
STUDENT’S DECLARATION
iii
ACKNOWLEDGEMENTS
iv
ABSTRACT
v
ABSTRAK
vi
TABLE OF CONTENTS
vii
LIST OF TABLES
x
LIST OF FIGURES
xi
CHAPTER 1
CHAPTER 2
INTRODUCTION
1.1
Introduction
1
1.2
Background of the Project
1
1.3
Problem Statement
2
1.4
Objective
2
1.5
Scope
2
1.6
Flow Chart
3
1.7
Gantt Chart
5
LITERATURE REVIEW
2.1
Introduction
6
2.2
Type of Remote Control Holder
6
2.2.1
6
Spinning Remote Control Holder
viii
2.2.2
2.2.3
2.2.4
2.3
2.4
CHAPTER 3
CHAPTER 4
Solid Hardwood Ebony Remote Control
Holder
Sofa Remote Control Holder
Sofa Over Arm Caddy
7
8
9
Type of Safety
9
2.3.1
2.3.2
2.3.3
10
10
11
Lock
Cable
Alarm
Fabrication Planning Process
12
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
12
12
13
14
15
16
Bending
Shearing
Lathe
Milling
Drilling
Welding
METHODOLOGY
3.1
Introduction
18
3.2
Process Flow
18
3.3
Phase 1-Establish Target Specification
19
3.4
Phase 2-Design Concept
19
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
20
20
21
21
22
Design Concept 1
Design Concept 2
Design Concept 3
Design Concept 4
Design Concept 5
3.5
Phase 3-Select Final Design
22
3.6
Phase 4-Searching Material for the Product
24
3.7
Phase 5-Fabrication of the Product
25
RESULT AND DISCUSSION
4.1
Introduction
30
4.2
Final Products
30
ix
4.2.1
4.2.2
Component of Final Products
Function of Final Product Component
4.3
How to Use This Remote Control Holder
32
4.4
Project Problem
33
4.4.1
4.4.2
4.4.3
4.4.4
33
33
33
33
4.5
Literature Review
Designing and Sketching
Material Preparation
Fabrication Process
How this Project Achieves the Objective
and Solves the Problem Statement
CHAPTER 5
31
32
34
CONCLUSION AND RECOMMENDATION
5.1
Introduction
35
5.2
Conclusion
35
5.3
Recommendation
35
5.3.1
35
Material Selection
REFERENCES
36
APPENDICES
38
A
Gantt Chart
38
B
Each Part of the Project with Dimension
39
C
Machine use
45
x
LIST OF TABLE
Table No.
Page
3.1
Process flow
18
3.2
Screening method
23
3.3
List of material
24
4.1
Function of every part
32
xi
LIST OF FIGURE
Figure No.
Page
1.1
Flow Chart
3
2.1
Spinning remote control holder
7
2.2
Solid Hardwood Ebony Remote Control Holder
8
2.3
Sofa remote control holder
8
2.4
Sofa over-arm caddy.
9
2.5
Lock
10
2.6
Cable
11
2.7
Sensor switch
11
2.8
Bending
12
2.9
Shearing Process
13
2.10
Important element of lathe machine
14
2.11
Slot Cut
15
2.12
Drilling Process
16
2.13
MIG Welding Process
17
3.1
First Design Concept
20
3.2
Second Design Concept
20
3.3
Third Design Concept
21
3.4
Fourth Design Concept
21
3.5
Fifth Design Concept
22
xii
3.6
Finalize design
24
3.7
Mild steel shaft and hollow shaft.
25
3.8
Remote control holder.
25
3.9
Remote control battery slot
26
3.10
key slot
26
3.11
Remote control holder door
27
3.12
Remote control holder support
27
3.13
Mild steel shaft
28
3.14
Mild steel hollow shaft.
28
3.15
Remote control holder part
29
3.16
Remote control holder support part.
29
3.17
Final product
29
4.1
Drawing final product
30
4.2
Final product (side view)
31
4.3
Component of final product
31
CHAPTER 1
INTRODUCTION
1.1
INTRODUCTION
CHAPTER 1 is the introduction chapter of this project. Generally, it discuss
about the project background, problem statement, the objective, scope of project, project
flow and project Gantt chart.
1.2
BACKGROUND OF THE PROJECT
Safety storage is one of the important things in our life. People need storage that
can secure their most important stuff. In order to reach it, manufacturer had come out
with ideas to produce some good storage which may help people to keep their stuff
safely.
Today, manufacturer had come with innovative and creative ideas to achieve
high productive for the competition with other manufacturers. As example, safety
storage today had come out with so many designs depending on their function and
working place.
In lecture room, there is one thing that needs to be secure. It is LCD remote
control that is use to monitor LCD projector. Innovative productivity means improving
efficiency in order to do the job well. Safety storage is needed so that it is easier to be
found and avoid people to steal and play with the remote.
2
1.3
PROBLEM STATEMENT
There is currently no holder available to secure the LCD remote control storage
in lecturer room at University Malaysia Pahang campus Pekan. I decide to design a
secured remote holder to make it easier to store and use the remote control in more
suitable placing and storing.
1.4
OBJECTIVE
The objective of this project is:
(i)
To design a secured holder in small in size in lecture room.
(ii)
To fabricate a secured LCD remote control holder.
1.5
SCOPE
In this project, scope performed a range in the completion of a project. The
scopes of this project are:
(i)
This study is focused on making a secured LCD remote control holder.
(ii)
Function to secure LCD remote control and easier to be found.
(iii)
This holder only for Sanyo LCD remote control.
(iv)
The holder secure by lock.
3
1.6
FLOW CHART
Start
Problem identification
Objective of the project
Scope of the project
New Conceptual Design or by Improving Market Design
No
Concept selection
Yes
Finalize Design
Fabrication
Verification
Result and Discussion
End
Figure 1.1: Flow Chart
4
The project starts identify the problem. It is a first step for the project flow in
order to find the problem in current product. This step helps to create a different design
to improve the product.
After identify the problem for the project, project continues with identify the
objective. The objective is very important in every work because every procedure to
make a project will depend on it. It will help to know the main point to make the project
success or not.
The project continues with identify the scope of the project because this scope
can help the progress to create the new product design for the project and to make sure
the method chose will be within the range of achievable objective.
Next continue it with literature review and research about the title. This consist a
review of the design of holder, and type of safety. These tasks have been done through
research on the internet.
From the flow chart, start to design new concept. Use datum as reference. Then
improve the design. Try to come with several concepts. Then compare the criteria from
each design which are the best. If the best design chosen still needed to be improved go
back to the previous step. If no improvement is needed go to next step. Produce the
drawing together with dimension of the product and the type of materials needed.
After completing the previous task, start the fabrication process. Gather the parts
needed for the project to proceeds the fabrication process.
Here come the testing and evaluation process. The secured LCD remote control
holder will be test to see if it full fills the requirement such as safety, ability and
strength. During the testing, if a problem occurs, the process of fabrication remote
holder will step back to the previous process. The reason to step back is to fix the error.
After all the parts had been joined together and no error, here comes the phase of
result and discussion. In this part, how the remote holder functions will be informs.
Beside, how to achieve objective and solve problem statement of the project will be
discuss in this phase.
5
1.7
GANTT CHART
Gantt chart is an important to guide work process during this project. With gantt
chart what need to be done first can be plan accordingly. Other than that, this project
will run smoothly and finish on time. Refer Appendix A to see a gantt chart that being
used for this project.
CHAPTER 2
LITERATURE REVIEW
2.1
INTRODUCTION
CHAPTER 2 is the literature review of the project. In this chapter, there is a type
of holder and safety. Besides that, it is consists with the design which were available at
the market.
2.2
TYPES OF REMOTE CONTROL HOLDER
There are two types of remote control holder are the table top holders, and the
sofa arm remote control holder. This is most common holder that has in market and use
by many people.
The table top remote holder made of metal, or wood, and look like caddies
similar to pen holders, with different compartments. Some come in very creative
designs, and can hold other things like magazine. Some are also made to spin.
Furthermore, the sofa arm remote control holder made of fabric and cotton. This
holder is fit with sofa arm. Some of this type come in very creative design and can hold
other things such as magazine, pen, glasses and snack table.
2.2.1
Spinning Remote Control Holder
This remote control holder based on Figure 2.1 made from brown leather. It has
four storage compartments for remote controls. Other than that, it can store a few DVD
7
or television channel listing at the large center compartment. The special of this holder is
can spins freely and allows easy access to all remotes.
Figure 2.1: Spinning remote control holder
Source: Remotecontrolholder
2.2.2
Solid Hardwood Ebony Remote Control Holder
This remote based on Figure 2.2 is made from wood. It just a simple table remote
holder. It can holds up to six remote in one time. This holder used for remote control
only.
8
Figure 2.2: Solid Hardwood Ebony Remote Control Holder
Source: Google image
2.2.3
Sofa Remote Control Holder
This type of remote control holder is fit over the sofa arm based on the Figure
2.3. It can washable and dryable. This holder provides three-pocket for remote control.
Figure 2.3: Sofa remote control holder
Source: Tobitas-crochet
9
2.2.4
Sofa Over-Arm Caddy
This holder based on Figure 2.4 made from durable fabric construction with a
stylish blue color. It has three sides; one of the sides has two large pockets for full
magazines. The other side has one large pocket and three smaller pockets for pens,
glasses and remotes control. Last part is flat surface in the center to keep items from
sliding off.
Figure 2.4: Sofa over-arm caddy
Source: organize
2.3
TYPES OF SAFETY
Safety is important to our life to secure the important thing. Without safety life is
dangerous and might feel worry all the time because need to care a important thing by
self. It has many types and each type depends on the thing that needs to be secured. The
most common type of safety is lock, cable, alarm and CCTV.
10
2.3.1
Lock
Lock has two types which is using a key based on Figure 2.5 or using a code.
Basic application of this lock is to lock motorcycle, house gate and locker.
Figure 2.5: Lock
Source: ambcomputers
2.3.2
Cable
These are simply the most effective and convenient. It is low cost range of PC
cable locks. Most of thing that secure by cable is laptop and computer based on Figure
2.6, hand phone display, iPod and camera.
11
Figure 2.6: Cable
Source: eos.ncsu
2.3.3
Alarm
Alarm has two types which is using sensor based on Figure 2.7 and switch. The
function of alarm is to alert when there is danger. Some examples of situation that use
alarm are flood and fire. As for vehicles alarm is widely use to prevent being stole.
Figure 2.7: Sensor switch
Source: geeky-gadgets
12
2.4
FABRICATION PLANNING PROCESS
2.4.1
Bending
Bending is a process by which metal can be deformed by plastically deforming
the material and changing its shape. The material is stressed beyond the yield strength
but below the ultimate tensile strength. The surface area of the material does not change
much. Bending usually refers to deformation about one axis.
Bending is a flexible process by which many different shapes can be produced.
Standard die sets are used to produce a wide variety of shapes. The material is placed on
the die, and positioned in place with stops and/or gages. It is held in place with holddowns. The upper part of the press, the ram with the appropriately shaped punch
descends and forms the v-shaped bend.
For this project I plan to use bending to make a remote control holder. The item
that will bend is zinc sheet metal. Figure 2.8 is example of bending.
Figure 2.8: Bending
Source: efunda
2.4.2
Shearing
Cutting processes are those in which a piece of sheet metal is separated by
applying a great enough force to cause the material to fail. The most common cutting